Capsules, heat-not-burn (HNB) aerosol-generating devices, and methods of generating an aerosol

Abstract

A capsule for an aerosol-generating device may include a first heater, a second heater, and a frame sandwiched between the first heater and the second heater. The frame may define open spaces therein and have a rigidity that is adequate to support the first heater and the second heater. The open spaces within the frame may be interconnected and sized for aerosol-permeability and capillary action. A nicotine-containing material, such as tobacco, may be disposed within the capsule.

The invention claimed is: 
     
       1. A capsule for an aerosol-generating device, comprising:
 a first planar heater; 
 a second planar heater; and 
 a frame sandwiched between the first planar heater and the second planar heater, the frame formed of consolidated fibers and configured as an underlying support structure for the capsule, 
 wherein the frame has a density between 0.454 g/cm 3  to 1.361 g/cm 3 , and 
 wherein a porosity of the frame is such that a pressure drop through the frame is in a range of 5 mm H 2 O to 200 mmH 2 O. 
 
     
     
       2. The capsule of  claim 1 , wherein at least one of the first planar heater or the second planar heater is in a form of a mesh. 
     
     
       3. The capsule of  claim 1 , wherein at least one of the first planar heater or the second planar heater is in a form of a perforated foil. 
     
     
       4. The capsule of  claim 1 , wherein the frame has a thickness between about 0.7 mm to about 1.3 mm. 
     
     
       5. The capsule of  claim 1 , wherein the frame includes nicotine. 
     
     
       6. The capsule of  claim 1 , wherein the frame defines a cavity. 
     
     
       7. The capsule of  claim 6 , wherein the cavity is a through-hole. 
     
     
       8. The capsule of  claim 6 , further comprising:
 an aerosol-forming substrate in the cavity of the frame, the aerosol-forming substrate configured to produce an aerosol when heated by at least one of the first planar heater or the second planar heater. 
 
     
     
       9. The capsule of  claim 8 , wherein the aerosol-forming substrate includes a fibrous material configured to release a compound as part of the aerosol. 
     
     
       10. The capsule of  claim 1 , wherein the frame is non-conductive and electrically isolates the first planar heater and the second planar heater. 
     
     
       11. The capsule of  claim 1 , wherein the frame is in a form of a multi-layer structure. 
     
     
       12. The capsule of  claim 11 , wherein the multi-layer structure of the frame includes different layers configured to impart distinct flavors. 
     
     
       13. The capsule of  claim 11 , further comprising:
 a third planar heater within the multi-layer structure of the frame. 
 
     
     
       14. The capsule of  claim 1 , wherein the consolidated fibers of the frame are plant-based fibers. 
     
     
       15. The capsule of  claim 14 , wherein the plant-based fibers are in a form of paperboard. 
     
     
       16. The capsule of  claim 14 , wherein the plant-based fibers are tobacco fibers. 
     
     
       17. The capsule of  claim 16 , wherein the tobacco fibers are in a form of a tobacco sheet.